Waterproof tape for automobile battery and manufacturing method thereof

ABSTRACT

The present invention provides a waterproof tape for an automobile battery which comprises a filler layer having formed on one side of a base film to exhibit excellent viscosity while being thin and has excellent shock resistance and an excellent waterproof property, and a manufacturing method.

BACKGROUND OF THE INVENTION

Field of the Invention

The present invention relates to a waterproof tape for an automobile battery and a manufacturing method, and more particularly to a waterproof tape for an automobile battery and a manufacturing method, which can effectively prevent penetration of water from a tight gap on components of an automobile battery assembly while being thin, and prevent damage caused by external impacts with excellent shock resistance.

Description of the Related Art

Generally, all automobiles contain various required equipment necessary for the operation thereof, including an ignition system for driving an engine, most of which is operated by electric power. Hence, the automobile includes a generator for supplying necessary power to devices using the electric power as power sources, wherein since the generator is driven by the engine, it always includes a battery for supplying operation power to the starting ignition system thereof. Further, the battery is connected to various electric units as well as the ignition system so as to operate each of the electric units as needed when the engine is not driven, and reversely, when the engine is being driven, the battery is charged by the generator.

Such a battery is generally installed in an engine room where various units are concentrated. However, since the automobile engine room is formed such that the front and the bottom thereof may communicate with the outside for radiating and cooling, particular attention to waterproofing of the battery is required. Thus, the battery is mounted to be located on a water level from the ground to the extent that the operation thereof is not disrupted, called, on the top of a wading line, even if there are puddles in a running rail of the automobiles like the rainy season, and the battery is waterproof in the structure that rainwater and the like penetrated from the top can be blocked.

However, for example, when a flooding part of the automobile is beyond the wading line by heavy rain and the like, the battery is wet to adversely affect the automobile operation as well as shortening a battery lifetime. Specifically, since a military truck is frequently driven underwater in the wading of a river, and the like, the problem from flooding of the battery becomes very serious. Thus, in the military truck, the battery might be installed in the inside of the truck. In this case, the battery can be waterproofed, but passengers have been too dissatisfied with harmful gas generated for the chemical reaction of the battery.

To solve such a problem, a scheme of mounting the battery outside the automobile on the top of the wading line is being pursued, but it is virtually impossible to install the battery outside the automobile by allowing the battery to come close to the engine room on the top of the wading line in view of the structural characteristic of the automobile.

Hence, a waterproof tape having an adhesive layer formed on a base thereof is being used according to various purposes such as connection, fixation and the like, of the components in the battery. Further, it has been known that in prior art waterproof tapes, for example, a foaming agent is used as the base to increase adhesion to an adhered object.

However, recently, as the automobile battery becomes smaller, lighter and thinner, and become more precise, it requires stricter water tightness. As a result, it is difficult to provide a waterproof property meeting such recent needs only by using the foaming agent as the base, and specifically, the tape finds difficulty in providing adhesion and waterproof properties at a level capable of sufficiently covering even a few gaps present in a member and an interface of the adhesive layer.

Furthermore, the waterproof tape can have the functions such as shock resistance and shock absorption, in addition to basic roles such as adhesion, water proofing, and the like. That is, the waterproof tape can serve as preventing the adhered objects from being damaged by absorbing a shock force without damage of the tape from the shock force applied to the adhered objects, simultaneously with preventing water from being penetrated between the adhered objects.

Conventional tapes have the foaming agents as the bases which may partially serve as such shock resistance and shock absorption. However, when the tapes are narrow or thin, they have the problem of insufficiently implementing the shock resistance and shock absorption functions.

PRIOR-ART DOCUMENT Patent Document

(Patent Document 1) Japanese Laid-Open Patent Publication No. 2001-152111

(Patent Document 2) Korean Laid-Open Patent Publication No. 2002-0014120

SUMMARY OF THE INVENTION Technical Problem

The present invention was made to solve the aforementioned problem occurring in the prior art, and it is an object of the present invention to provide a waterproof tape for an automobile battery which exhibits excellent viscosity, adhesion and shock resistance to an adhered object while being thin, in order to maximize watertightness of the automobile battery and has a water-proof property at a level capable of effectively covering even a few gaps present in a member and an interface of an adhesive layer, and a manufacturing method.

Technical Solution

The present invention provides a waterproof tape for an automobile battery and a manufacturing method. A double-sided tape comprises a base film having a filter layer formed on the side thereof and an adhesive layer, wherein the filler layer comprises a shock resistant filler containing an acrylic binder and a plurality of hollow fine particles, and the hollow fine particle comprises a first coating film which consists of a thermoplastic material containing 15-40 parts by weight of a monomer, with respect to a total of 100 parts by weight, and has a hollow part.

In accordance with another preferable embodiment, the hollow fine particles may further comprise a second coating film containing 50-80 parts by weight of calcium carbonate, with respect to a total of 100 parts by weight, and disposed arranged along the circumference of the first coating film.

In accordance with another preferable embodiment, the filler layer may comprise 5-60 parts by weight of the shock resistant filler, with respect to 100 parts by weight of the acrylic binder.

In accordance with another preferable embodiment, the monomer of the first coating film may be a copolymer comprising at least one of 15-40 parts by weight of acrylonitrile, with respect to 100 parts by weight of the hollow fine particles, phosphate methacrylate and alkali strippable polyester acrylate.

In accordance with another preferable embodiment, the base film has turned black, and the black coloring agent may comprise at least one of carbon black and iron sulfide.

In accordance with another preferable embodiment, the filler layer has turned black, and the black coloring agent may comprise at least one of carbon black and iron sulfide.

An embodiment of the present invention provides a method for manufacturing a waterproof tape for an automobile battery by forming an adhesive layer on at least one side of a base film, wherein the base film forms a filler layer by coating a paste containing a shock resistant filler having an acrylic binder and a plurality of hollow fine particles on one side thereof, and the hollow fine particles are manufactured by the steps of: preparing a hydrogen dispersion by inputting 2-6 parts by weight of liquid hydrocarbon with respect to a total of 100 parts by weight and a dispersing agent into water; preparing a particulate crystal by inputting 15-40 parts by weight of a monomer into the hydrogen dispersion, with respect to a total of 100 parts by weight of the hollow fine particles, and forming a first coating film on the circumference of the hydrocarbon; forming an unexpanded microsphere by heating the particulate crystal and removing the hydrocarbon; and preparing an expanded microsphere by heating the unexpanded microsphere to expand the first coating film.

In accordance with another preferable embodiment, the hollow fine particles may be manufactured by further comprising the step of forming a second coating film with 50-80 parts by weight of calcium carbonate, with respect to a total of 100 parts by weight of the hollow fine particles, on the circumference of the first coating film of the expanded microsphere.

In accordance with another preferable embodiment, in the step of preparing the hydrogen dispersion, the liquid hydrocarbon may comprise 1-10 parts by weight of 2-methylbutane and 1-10 parts by weight of 2-methylpropane, with respect to a total of 100 parts by weight of the hollow fine particles.

In accordance with another preferable embodiment, in the step of preparing the hydrogen dispersion, the dispersing agent may be a surfactant.

In accordance with another preferable embodiment, in the step of preparing the particulate crystal, the monomer may be a copolymer of 15-40 parts by weight of acrylonitrile with respect to a total of 100 parts by weight of the hollow fine particles, and other acrylic groups.

In accordance with another preferable embodiment, in the step of preparing the expanded microsphere, the unexpanded microsphere may be heated at a temperature of 170-190° C.

In accordance with another preferable embodiment, the step of forming the second coating film may comprise the steps of: inputting the expanded microsphere and the calcium carbonate into a reactor, and inserting air thereto at a temperature of 130-150° C., thereby floating the expanded microsphere and the calcium carbonate inside the reactor; and forming a second coating film while embedding the calcium carbonate in an outer wall of the first coating film of the expanded microsphere.

In accordance with another preferable embodiment, the base film has turned black, and the black coloring agent may comprise at least one of carbon black and iron sulfide.

In accordance with another preferable embodiment, the filler layer has turned black, and the black coloring agent may include at least one of carbon black and iron sulfide.

Effects of the Invention

The waterproof tape for an automobile battery according to the exemplary embodiment of the present invention exhibits excellent adhesion to an adhered object while being thin, thereby effectively preventing penetration of water from a tight gap on a component of an automobile battery assembly, and has excellent shock resistance to prevent damage caused by external impacts, even if the tape is narrow or thin.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side sectional view of a waterproof tape according to an exemplary embodiment of the present invention.

FIG. 2 is a graph showing the result of comparing adhesion tests between embodiments of the present invention and comparative examples.

FIG. 3 is a graph showing the result of comparing shock resistance tests between embodiments of the present invention and comparative examples.

FIG. 4 is a flowchart of a method for manufacturing a waterproof tape according to an exemplary embodiment of the present invention.

FIG. 5 is a flowchart of a method for manufacturing a shock resistant filler of a filler layer in the waterproof tape according to an exemplary embodiment of the present invention.

FIG. 6 is a configuration view of schematically showing a reactor for forming a second coating film on an expanded microsphere according to an exemplary embodiment of the present invention.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Hereinafter, exemplary embodiments in the present disclosure will be described in detail with reference to the accompanying drawings. The disclosure may, however, be exemplified in many different forms and should not be construed as being limited to the specific embodiments set forth herein.

Unless explicitly stated to the contrary, the word “comprise,” “comprises” or “comprising” used throughout the specification will not be understood as the exclusion of the other elements but to imply the inclusion of the other elements.

FIG. 1 is a side sectional view of a waterproof tape according to an exemplary embodiment of the present invention.

With reference to FIG. 1, a waterproof tape 100 is basically configured to arrange an adhesive layer on at least one of a base film 10 having a filler layer 20. In the exemplary embodiment, it is shown and described that first and second adhesive layers 30, 40 are respectively arranged on both sides of the base film 10, but the adhesive layer can be formed only on an upper side of the filler layer 20 or on an upper part of the base film 10, as needed.

Herein, the waterproof tape 10 may be formed, for example, at a thickness of 10-300 μm so as to easily secure adhesion to an adhered object. The thickness of the tape 100 is formed like this, and thus can be easily applied in assembling an automobile battery assembly, and can implement a favorable waterproof function as well as increasing the adhesion.

The base film 10 which is a layer to be a base of the tape 100, is used for fixation and the like of electronic and mechanical parts of the automobile battery assembly, and may be preferably formed of polyethylene terephthalate (hereinafter referred to as “PET”), but the present invention is not limited thereto. For example, the base film 10 may be manufactured by applying graphite with excellent heat resistance and heat conductivity or a conductive material for the addition of radiating and conductive functions.

Further, for example, a urethane base and the like may be applied to a primer applied to the base film 10, but the present invention is not limited thereto. The PET has an advantage of securing workability of easily removing the tape when the defects were generated due to wrong assembling at the adhesive layer, and reassembling as needed.

Further, the thickness of the base film 10 may be, for example, 20-40 μm. For example, when a total thickness of the tape 100 is 250 μm or less, the thickness of the base film 10 may be about 23 μm, and when the total thickness of the tape 100 is greater than 250 μm, and, for example, the total thickness is about 300 μm, the thickness of the base film 10 may be about 38 μm.

Herein, when the thickness of the base film 100 is less than 20 μm, the problem of lowering heat resistance of the tape 10 and shortening a material may occur, and when the thickness of the base film 10 is greater than 40 μm, because the filler layer 20, the first and second adhesive layers 30, 40 and the like should be relatively thinly formed, the shock resistance and the adhesion of the tape 100 may be decreased, which is problematic. However, the thickness of the base film of the tape of the present invention is not necessarily limited to the numerical values described above.

Herein, when the tape 100 is used for shading the light, the base film 10 may turn black, and when the tape 100 is used for reflecting the light, the base film 10 may turn white. When the base film 10 colors like this, the adhesive forces to the first and second adhesive layers 30, 40 respectively disposed on upper and lower sides of the base film 10 can be improved.

Herein, the black coloring agent may comprise at least one of carbon black capable of exhibiting black and iron sulfide. Further, the carbon black may use a urethane-based resin as a binder. The urethane-based resin has a stable physical property, and an excellent adhesive force to an acrylic-based adhesive layer. In the present invention, the black coloring agent may be manufactured by mixing part of various materials according to the color and the physical property as needed. However, the black coloring agent of the present invention is not limited to the specific ingredient or the content described above.

The filler layer 20 is formed on the upper side of the base film 10. Further, the thickness of the filler layer 20 varies according to the total thickness of the tape 100, and may be, for example, 60-80 μm.

Further, a surface of the filler layer 20 may turn black as needed. When the surface of the filler layer 20 turns black, the function of shading the light is given to the filler layer 20 and the degradation of the reliability for partial defects due to the function of shading the light can be prevented. Herein, the black coloring agent may comprise at least one of carbon black and iron sulfide.

In a prior-art tape having a PE-foam structure, a PE-foam may be transferred to a base film or an adhesive layer in contact vertically in reworking. However, since the exemplary embodiment of the present invention contains the filler layer 20 and does not use the PE-foam, it does not cause such a problem.

Such a filler layer 20 may be formed by coating a paste containing an acrylic binder and the shock resistant filler on the upper side of the base film 100.

The acrylic binder may be formed of, for example, acrylonitrile. However, the present invention is not limited thereto. Meanwhile, the filler layer 20 may further comprise additives such as a cross linker, a tackifier and the like, as needed. The additives may be added at a content of 0.1-30 parts by weight, with respect to 100 parts by weight of the acrylic binder. However, the present invention is not limited thereto.

Further, shock resistance and density of the filler layer 20 may vary according to the content of the shock resistant filler contained in the acrylic binder. For example, the shock resistant filler may comprise 5-60 parts by weight with respect to 100 parts by weight of the acrylic binder.

Since the shock resistant filler is an impurity, when it exceeds 60 parts by weight with respect to 100 parts by weight of the acrylic binder, it has a low combination with the acrylic binder. Hence, as the paste is split and coating is not available, the original function of the shock resistant filler cannot be carried out. Further, when the content of the shock resistant filler is less than 5 parts by weight with respect to 100 parts by weight of the acrylic binder, the problem of lowering the shock resistance and repellent resistance may occur.

Further, the shock resistant filler comprises a plurality of hollow fine particles 21 with low density. Herein, the hollow fine particles 21 have proper cushiness and can provide excellent shock resistance. As a result, even if a certain level of vibration or shock is given to the automobile battery, the shock resistant filler can endure the vibration or shock, and absorb the vibration or shock to prevent damage of the adhered object.

The hollow fine particles 21 are particles having hollow parts formed therein, and may be manufactured in various forms in a various methods. Exemplary embodiments will be described below.

Further, the hollow fine particles 21 may comprise liquid hydrocarbon and a first coating film having a hollow part disposed on an outer surface thereof by referring to the liquid hydrocarbon as a nucleating agent. After the liquid hydrocarbon serves as forming the first coating film, it is removed in a polymerizing process described below.

The liquid hydrocarbon may comprise, for example, 1-10 parts by weight of 2-methyl butane, and 1-10 parts by weight of 2-methyl propane, with respect to 100 parts by weight of the hollow fine particles 21.

Herein, in the liquid hydrocarbon, when the content of the 2-methyl butane is less than 1 part by weight, inner expansion is insufficient in manufacture of the hollow fine particles 21, and thus the problem of lowering the shock resistance of the hollow fine particles 21 may occur. Further, when the content of the 2-methyl butane is greater than 10 parts by weight, there is overexpansion in manufacture of the hollow fine particles 21, and thus the hollow fine particles 21 do not keep a constant type to lower uniformity, thereby decreasing an overall physical property.

Further, when the content of the 2-methyl propane is less than 1 part by weight, inner expansion is insufficient in manufacture of the hollow fine particles 21, and thus the problem of lowering the shock resistance of the hollow fine particles 21 may occur. Further, when the content of the 2-methyl butane is greater than 10 parts by weight, there is overexpansion in manufacture of the hollow fine particles 21, and thus the hollow fine particles 21 do not keep a constant type to lower uniformity, thereby decreasing an overall physical property.

The first coating film may comprise a thermoplastic material containing a monomer. The thermoplastic material may comprise 15-40 parts by weight with respect to a total of 100 parts by weight of the hollow fine particles 21. The thermoplastic material may comprise, for example, a copolymer of acrylonitrile and other acrylic groups, but the thermoplastic material of the present invention is not limited thereto. The other acrylic groups may comprise phosphate methacrylate, alkali strippable polyester acrylate and the like.

Herein, when the content of the thermoplastic material is less than 15 parts by weight, because it has an impact on crosslink density, a coating treatment may not be smoothly performed. Further, when the content of the thermoplastic material is greater than 40 parts by weight, because it has an impact on the content of the shock resistant filler, the shock resistance and the reliability may be lowered.

The first coating film supplies elastic and restoring forces to the tape 100, and supplies the shock resistance thereto to serve as supply of a tolerance to mechanical distortion. For example, even if a load of about 0.7 Mpa is repetitively applied to the tape 100, the tape 100 is not damaged with the elastic and restoring forces of the first coating film.

Meanwhile, the hollow fine particles 21 may further comprise a second coating film arranged along the circumference of the first coating film, as needed.

The second coating film may comprise 50-80 parts by weight of calcium carbonate with respect to 100 parts by weight of the hollow fine particles 21. The second coating film improves a shattering property of the liquid hydrocarbon, and improves dispersibility in a resin of the first coating film, thereby having an effect of further improving the shock resistance of the hollow fine particles 21.

Further, the second coating can increase a gravity of the hollow fine particles 21 while preventing the hollow fine particles 21 from being condensed in the shock resistant filler, and can serve as improving a mixing property.

Herein, when the content of the calcium carbonate is less than 50 parts by weight, workability may be decreased because of shattering the shock resistant filler, and when the content of the calcium carbonate is greater than 80 parts by weight, the shock resistance may be lowered.

Meanwhile, the diameter of the hollow fine particles 21 of the exemplary embodiment of the present invention may be 10-50 μm, wherein an inner through-hole which the liquid hydrocarbon occupies in the step of manufacturing the hollow fine particles 21 accounts for 95%, and the thicknesses of the first and second coating films may be 1 μm or less in totality. The diameter of the hollow fine particles 21 keeps the uniformity of a product in the foregoing scope to minutely adjust the level of illumination, thereby ensuring a step compensation of the product and stability of the adhesive power. However, the present invention is not limited thereto.

Meanwhile, since the filler layer 20 uses the hollow fine particles 21 having the uniform diameter described above, it has an excellent level of illumination in general. In addition, since it is soft like a sponge, it properly fills even the nonuniform level of illumination of an injection product, thereby securing the adhesive power and the reliability.

The first and second adhesive fillers 30, 40 are formed on an upper side of the filler layer 20, and a lower side of the base film 10, respectively. The first and second adhesive fillers 30, 40 may be formed of, preferably, an acrylic-based pressure sensitive adhesive agent, but the present invention is not limited thereto. Further, the first and second adhesive fillers 30, 40 can adjust the contents of e-EHA, CHMA and nBA, so as to embody excellent water resistance, adhesive power and reliability in polymerization of the acrylic-based adhesive agent.

Herein, the first and second adhesive layers 30, 40 may have different adhesive powers according to adhered objects. Hence, the first adhesive layer 30 may be formed to have a different thickness, and, for example, it may be formed to be thicker by about 10 μm than the second adhesive layer 40 formed between the base film 10 and a release layer 50.

Further, as the first adhesive layer 30 or the second adhesive layer 40 gets thicker by a critical thickness, the adhesive power thereof is increased. Thus, the adhesive layer is made as thick as possible, from which the adhesive power can be improved, and also, the adhesive layer itself can provide a constant cushioning property. When the first adhesive layer 30 or the second adhesive layer 40 is too thin, the adhesion is lowered, and when the first adhesive layer 30 or the second adhesive layer 40 is too thick, it may have an impact on blanking molding in a blanking process.

Further, the first and second adhesive layers 30, 40 controls their softness by adjusting crosslink density, thereby further improving the shock resistance and providing a step compensation effect according to a stacking structure. Herein, the crosslink density can be adjusted by controlling the kinds and the contents of hardening agents.

The release layer 50 may be formed on a lower side of the second adhesive layer 40, as needed. The release layer 50 serves as preventing the finished tape 100 from having foreign substance or being damaged when the tape 100 is stored or transported.

The release layer 50 can uses, for example, a product in which a PE film is connected to paper, and silicon is release-treated on an outer surface of the PE film. However, the present invention is not limited thereto. Acryl and silicon are incompatible and are not thus coupled to each other, and as a result, an acrylic adhesive agent may use a product in which the release film is silicon-treated. For example, the release product 50 may use the product in which silicon is release-treated in glassine and PET goods.

In an exemplary embodiment of the present invention, the thickness of the paper may be 70-80 μm, and the PE film of which the thickness is 30-40 μm may be used on its double sides. Further, for the release-treatment of the silicon, the silicon may be coated with a thin film having a thickness of 1 μm or less. Herein, according to the kind of the used silicon, release powers and transition rates of the release layer 50 may be different, and, typically, the release layer 50 uses the transition rate of 90% or more. Herein, the transition rate indicates a numerical value of moving silicon to acryl, wherein the low transition rate indicates the small change in a physical property.

Herein, from the comparison between the comparative examples and the embodiments of the present invention, the excellent characteristics of the double-sided tape according to the embodiments of the present invention will be described below.

Comparative Example 1 shows a double-sided tape having an acrylic-foam structure having a total thickness of 200 μm, Comparative Examples 1 to 4 show double-sided tapes having polyethylene-foam structures of which total thicknesses are 250 μm, 200 μm and 200 μm, respectively, and Embodiments 1 to 3 show double-sided tapes having filler layers of which total thicknesses are 200 μm, 250 μm and 300 μm, respectively.

Herein, in Embodiment 1, the thicknesses of the first and second adhesive layers were 60 μm, and the thickness of the filler layer was 60 μm. In Embodiment 2, the thicknesses of the first and second adhesive layers were 70 μm, and the thickness of the filler layer was 70 μm. In Embodiment 3, the thicknesses of the first and second adhesive layers were 90 μm, and the thickness of the filler layer was 80 μm. In Embodiments 1 to 3, the contents of the shock resistant fillers in all the filler layers used 35 parts by weight with respect to 100 parts by weight of the acrylic binder.

Hereinafter, Embodiments 1 to 3 will be referred to as “the embodiments” and described as needed when describing features irrelevant to the total thickness.

An adhesive power test is called an ASTM D 3330 test, wherein the double-sided tapes of the comparative examples and the embodiments adhered to an SUS board, a PC board and glass, respectively, by reciprocating 2 kg of a rubber compressing roller one time at a velocity of 300 mm/min, and then, they were left for 30 minutes at room temperature. The forces (gf/25 mm) of detaching the double-sided tapes from adhered objects were measured.

With reference to FIG. 2, as a result of the measurement, it can be confirmed that both upper and lower sides in Embodiments 1 to 3 are similar to or have relatively higher force values than those of Comparative Examples 1 to 4. Thus, it can be known that the double-sided tapes having the filler layers of the embodiment of the present invention are similar to or have more excellent adhesion than the double-sided tapes having the acrylic foam or the PE-foam (Comparative Examples 1 to 4).

As a result, the comparative examples should additionally use an adhesive so as to reduce a difference of such adhesion. The use of the adhesive makes it impossible to carry out rework of separating the double-sided tape from the adhered object and reassembling it as needed, and also leads to several problems such as rise in costs, a complicated manufacturing process and the like.

The test of the shock resistance is for measuring a restoring force according to pressure applied to the product. With reference to FIG. 3, as a result of the measurement, the embodiments have a smaller change in the thickness as per the pressure applied to the product than the comparative examples, and have a smaller compression rate as per the pressure applied to the product than the comparative examples. Herein, the unit of a compression thickness is μm, the unit of a compression str. is mPa, and the unit of a compression rate is %. In the test of the shock resistance, conventional products using the PE-foam are used only in Comparative Examples 2 and 3.

In general, when the tapes adhere to an upper plate and a lower plate, there may be cracks or peeling on the adhered upper and lower plates due to artificial impacts. The test result shows that in the comparative examples, when the characteristic of low elasticity and low density and the pressure are applied to the tapes, they have slow restoring forces. In contrast, in the embodiments, the shock resistant filler formed of the hollow fine particle of the filler layer play a role as a spring to improve the shock resistance with the characteristic of high elasticity and high density, and when pressure is applied to the tapes, they have fast restoring forces.

It can be expected that the shock resistance of the tape according to the exemplary embodiments of the present invention is more improved by average 300% or more than the comparative examples. Thus, the embodiments have a compression rate of about 50% for the comparative examples, and have excellent repellent resistance to restrain impacts from being applied to an ITO sensor although the tape is not made thick. Thus, it can be known that even if the product having a thickness of 300 μm to which the comparative examples applies is manufactured to have the thickness of 200-250 μm in the embodiments, it can exhibit the shock resistance equal to or superior to that of the embodiments.

Meanwhile, the difference of the shock resistance of the tape may cause a remarkable difference even in a waterproof property of the adhered object because of the cracks or peeling. That is, even if the tapes are manufactured to have the same thickness, the tapes in the comparative examples and the embodiments have remarkably different shock resistance.

In other words, according to the embodiments of the present invention, waterproofing performance of IPx7 or more can be implemented due to such shock resistant difference, while the comparative examples implements much lower waterproofing performance than the embodiments. Herein, IP means IP_Ingress Protection rating, the first number x indicates classifying a grade for a dust proof function into 0-6, and the second number indicates classifying a grade for a waterproof function into 0-9 k. A higher number indicates excellent performance.

Further, in the tapes according to the embodiments of the present invention, since pressure in adhering by the filler layer focuses on a binding portion to easily extrude air present in an adhesion interface, excellent adhesion that prevents a gap through which water are penetrated can be implemented, in connecting rigid bodies, thereby improving a waterproof property.

Further, according to the exemplary embodiment of the present invention, a thickness direction of the tape has more excellent step compensation by the filler layer than the comparative example, which can give a great advantage to the waterproof property.

Meanwhile, the conventional tapes have a so-called open cell structure that a foaming agent is inserted into a PE resin in manufacture to make openings, and the openings give rise to cushiness. Herein, they have problems such as a big thickness deviation of 20-30 μm, and an ununiform surface.

However, the waterproof tape 100 according to the exemplary embodiment of the present invention does not use such a PE-foam, and has a so-called closed cell structure using the shock resistance filler layer. Thus, in accordance with the embodiment, since the thickness of the tape is adjusted by coating unlike the conventional double-sided tape having the open cell structure, the tape can have a uniform thickness on the whole. Also, since the filler layer is formed by a coating process, its thickness can be easily adjusted to have excellent productivity and wetting. In the conventional PE-foam, it is difficult to have a distribution value of a uniform thickness.

In addition, the tensile strength of the adhesive layer and the filler layer may be about 2 kgf/mm², and the physical property may be 30 kgf/mm² or less according to the tensile strength of PET as the base film.

The waterproof tape of the embodiment has easy adhesion to the adhered object, and can effectively prevent penetration of water from a tight gap to have an excellent waterproof property. However, the waterproof tape enables slimness, and can be also used effectively in fastening of an automobile battery assembly requiring strict watertightness.

Hereinafter, a method for manufacturing a waterproof tape 100 according to an exemplary embodiment of the present invention will be described below.

FIG. 4 is a flowchart of a method for manufacturing a waterproof tape according to an exemplary embodiment of the present invention.

With reference to FIG. 4, the base film 10 is first prepared (S1). Herein, the base film 10 may turn black as needed. Further, the black coloring agent may use at least one of carbon black and iron sulfide. Furthermore, it is preferable to properly mix and use the carbon black or the iron sulfide to prevent part of the base film 10 from being lumped to turn. The carbon black or the iron sulfide is preferably sufficiently stirred at 300 rpm or less for 10-30 minutes so as not to affect uniform stirring and a physical property. However, the present invention is not limited thereto.

Next, the filler layer 20 is formed by coating a paste containing a shock resistance filler having the acyclic binder and a plurality of hollow fine particles 21 on the upper side of the base film 10 (S2). Herein, the shock resistant filler may comprise 5-60 parts by weight with respect to 100 parts by weight of the acrylic binder. Further, it may further comprise an additive containing 0.1-30 parts by weight of a cross linker, as needed. Herein, the filler layer 20 may turn black as needed.

FIG. 5 is a flowchart of a method for manufacturing a shock resistant filler of the filler layer in the waterproof tape according to an exemplary embodiment of the present invention. With reference to FIG. 5, an exemplary embodiment of a method for manufacturing the hollow fine particle is described as follows.

First, 2-20 parts by weight of liquid hydrocarbon and a dispersing agent are inputted into 0.1-1 parts by weight of water, with respect to a total of 100 parts by weight of the follow fine particle 21. Herein, the liquid hydrocarbon may comprise, for example, 1-10 parts by weight of 2-methylbutane and 1-10 parts by weight of 2-methylpropane. Further, the dispersing agent may be a moderate amount of a surfactant. Thereafter, the hydrogen dispersion is prepared by dispersing the liquid hydrocarbon not mixed with water, at a certain size, by using the surfactant (S21).

Further, herein, additives such as a cross linker and the like may be further inputted thereto, as needed. The size limitation of the additives can be adjusted by the gravity. When the size of the filler gets bigger, and porous layers of the hollow fine particles grow bigger, the filler layer 20 has a low gravity, and when the filler gets smaller than the standard, the porous layers of the hollow fine particles get smaller, and the gravity thus grows bigger.

Thereafter, a thermoplastic material containing a monomer is inputted into the dispersed liquid hydrocarbon, the dispersed liquid hydrocarbon is referred to as a nucleating agent, and then, a first coating film having a band shape to surround the liquid hydrocarbon is formed, thereby preparing a particulate crystal (S22).

Herein, the monomer may comprise a copolymer of 15-40 parts by weight of acrylonitrile with respect to a total of 100 parts by weight of the hollow fine particles and other acyclic groups.

Thereafter, the particulate crystal having the first coating film formed thereon is polymerized (S23). The polymerization is that for example, 0.1-5.0 parts by weight of a polymerization initiator is added to the liquid hydrocarbon and is heated at a temperature of 140-150° C. for 10-60 minutes, from which the particulate crystal is heated to remove the hydrocarbon, thereby preparing an unexpanded microsphere is prepared (S24). Herein, the polymerization may proceed through a manner of separating the first coating film from the liquid hydrocarbon with a difference of the gravity, as needed.

Thereafter, the unexpanded microsphere is heated, for example, for 10-60 minutes to expand the diameter of the first coating film, and as a result, an expanded microsphere having an expanded volume in comparison with the originally provided unexpanded microsphere is prepared (S25). Herein, the unexpanded microsphere may be heated, for example, for 110-190° C., and more preferably, for 130-170° C. However, the present invention is not limited thereto. When the heating temperature is less than 110° C., microsphere is insufficiently expanded, which may lead to the problem of lowering repellent resistance and chemical stability of the hollow fine particles. Further, when the heating temperature is greater than 190° C., since the repellent resistance is lowered, chemical resistance and storage stability are vulnerable, and it may be difficult to implement the characteristic of the product.

That is, when the liquid hydrocarbon is referred to as the nucleating agent, and the outer wall is surrounded by an acrylic monomer, the particulate crystal is polymerized to remove the liquid hydrocarbon. Then, the first coating film is expanded to form the microsphere which has the porous layer formed thereon, has a hollow part and has an expanded volume, thereby manufacturing the shock resistant filler having the expanded microsphere.

Thereafter, a second coating film containing 50-80 parts by weight of calcium carbonate with respect to a total of 100 parts by weight of the hollow fine particles may be further disposed on the circumference of the first coating film of the expanded microsphere, as needed.

With reference to FIG. 6, in the second coating film, for example, the expanded microsphere (M) and calcium carbonate (C) are inserted into a main body 210 of a reactor 200 through injection parts 221, 224 formed in a pipe shape, and hot air having a temperature of about 130-150° C. is inserted thereto through an air supply part 251, thereby allowing the expanded microsphere (M) and the calcium carbonate (C) to float in the main body 210 of the reactor 200. In this state, the second coating film may be progressed to be formed while the calcium carbonate (C) bumps against the circumference of the first coating film of the expanded microsphere (M) and is embedded therein.

Herein, the velocity of supplying the air inserted into the main body 210 of the reactor 200, and the like, can be controlled to the extent that the expanded microsphere (M) and the calcium carbonate (C) can properly float and flow in the main body 210 of the reactor 200. Further, in the main body 210, a rotating shaft 231 having a propeller 231 a may be installed to circulate the inserted air, the expanded microsphere (M) and the calcium carbonate (C) and to more smoothly form the second coating film.

Further, the temperature of the air makes the first coating film tender to easily embed the calcium carbonate (C) on the circumference thereof. However, the temperature of the air according to the present invention is not limited thereto. Furthermore, in a lower end of the main body 210, a discharge part 241 having a valve 241 a may be prepared to discharge the microsphere (M) having the second coating film formed thereon.

The second coating film serves as restraining condensation and a shattering property of the expanded microsphere (M). Further, the density is measured by comparing the amount of the thermoplastic material inputted in the foregoing step and the amount and weight of a plurality of hollow fine particles finally completed, as needed. Thus, the density can be uniformly maintained at all times. Furthermore, the filler in the embodiments is light in a hardening process to floats at the top, all of which escapes in air.

Meanwhile, by randomly extracting samples and measuring their gravities, it can be confirmed whether the filler layer 20 has a uniformly sized distribution or not. When the filler layer 20 comprises large numbers of big fillers, it is lighter than a suitable standard sample, and when it comprises large numbers of small fillers, it is heavier than the suitable standard sample.

In accordance with the embodiments, as described above, the danger of extinguishing the liquid hydrocarbon in the filler layer at a high temperature, and shattering the particles of the porous layer may occur. However, the second coating film gives a fixed weight to the expanded microsphere (M) to improve the dispersibility of the first coating film of the expanded microsphere (M). As a result, the second coating film serve as preventing the hollow fine particles 21 from be shattered, and can provide an effect of improving the shock resistance of the hollow fine particles 21.

Further, the second coating can serve as increasing gravities of the hollow fine particles 21 while preventing the hollow fine particles 21 from being condensed in the shock resistant filler, and can serve as improving a mixing property.

Herein, the second coating film may comprise 50-80 parts by weight of calcium carbonate with respect to 100 parts by weight of the hollow fine particles 21. Herein, when the content of the calcium carbonate is less than 50 parts by weight, workability may be decreased because of shattering the shock resistant filler, and when the content of the calcium carbonate is greater than 80 parts by weight, the shock resistance may be lowered.

Next, the first and second adhesive layers 30, 40 are formed on the upper side of the filler layer 20 and the lower side of the base film 10, respectively (S3).

Next, the release layer 50 is formed on the lower side of the second adhesive layer 40 to complete the waterproof tape (S4).

The present invention should not be construed as limited to the embodiments set forth herein and the accompanying drawings, and is only defined by scopes of claims.

Thus, it will be apparent to those skilled in the art that replacements, modifications, and variations can be made without departing from the spirit and scope of the invention.

-   -   10; a base film     -   20; a filler layer     -   21; hollow fine particles     -   30, 40; first and second adhesive layers     -   50; a release layer     -   100; a tape     -   200; a reactor 

What is claimed is:
 1. A method for manufacturing a waterproof tape for an automobile battery, comprising: preparing a base film; disposing an adhesive layer on one side of the base film; and disposing a filler layer on another side of the base film by coating a paste including an acrylic binder and a shock resistant filler having a plurality of hollow fine particles, wherein the plurality of hollow fine particles are manufactured by the steps of: preparing a hydrocarbon dispersion by adding 2-20 parts by weight of liquid hydrocarbon with respect to a total of 100 parts by weight of the hollow fine particles and a dispersing agent having a surfactant into water; preparing a particulate crystal by adding 15-40 parts by weight of a thermoplastic material into the hydrocarbon dispersion, with respect to the total of 100 parts by weight of the hollow fine particles, and forming a first coating film by the thermoplastic material surrounding the dispersed liquid hydrocarbon; forming an unexpanded microsphere by heating the particulate crystal and removing the dispersed liquid hydrocarbon; and forming an expanded microsphere constituting each of the plurality of hollow fine particles by heating the unexpanded microsphere and expanding the first coating film.
 2. The method of claim 1, wherein the plurality of hollow fine particles are manufactured by further the step of forming a second coating film with 50-80 parts by weight of calcium carbonate with respect to the total of 100 parts by weight of the hollow fine particles, on a circumference of the first coating film of the expanded microsphere.
 3. The method of claim 2, wherein the step of forming the second coating film comprises the steps of: inputting the expanded microsphere and the calcium carbonate into a reactor, and inserting air thereto at a temperature of 130-150° C., thereby floating the expanded microsphere and the calcium carbonate inside the reactor; and forming a second coating film by embedding the calcium carbonate on an outer wall of the first coating film of the expanded microsphere.
 4. The method of claim 1, wherein the liquid hydrocarbon comprises 1-10 parts by weight of 2-methylbutane and 1-10 parts by weight of 2-methylpropane, with respect to the total of 100 parts by weight of the hollow fine particles, in the step of preparing the hydrocarbon dispersion.
 5. The method of claim 1, wherein the thermoplastic material is a copolymer of acrylonitrile and one or more of phosphate methacrylate and alkali strippable polyester acrylate, in the step of preparing the particulate crystal.
 6. The method of claim 1, wherein the unexpanded microsphere is heated at a temperature of 70-190° C., in the step of forming the expanded microsphere.
 7. The method of claim 1, wherein the base film is colored with the black coloring agent having at least one of carbon black and iron sulfide in the step of preparing the base film.
 8. The method of claim 1, wherein the filler layer is colored with the black coloring agent having at least one of carbon black and iron sulfide in the step of disposing the filler layer. 